Process for preparing a catalyst containing titania-supported titanosilicate

Abstract: Olefinic compounds are selectively oxidized using hydroperoxides, especially aqueous solutions of hydrogen peroxide in high yield and with good selectivity in the presence of a titania-supported titanosilicate catalyst. Dilute aqueous hydrogen peroxide solutions may be used with good results. The resulting epoxidation, even when carried out at modest temperatures and with dilute aqueous hydrogen peroxide solutions, afford superior results in epoxidation relative to TS-1.

Description: The present invention relates to a method of producing a catalyst comprising a titanosilicate impregnated on titania by hydrothermal crystallization of the titanosilicate. One of the most challenging and formidable tasks in preparative organic chemistry is the selective functionalization of hydrocarbons. Once a functional group has been introduced the chemist has a rich selection of tools to achieve further transformations and transpositions, but the initial barrier of introducing a functional group is determinative of further chemistry. Not only is it necessary that a given functionalization reaction proceeds in good yield, but it is necessary also that it proceeds with specificity. One of the most chemically attractive entry points to functionalization of hydrocarbons is the carbon-carbon double bond in alkenes and substituted alkenes, for the carbon-carbon double bond undergoes many reactions which introduce functional groups onto one or both of the carbons, and the double bond also activates an adjacent C-H bond (i.e., allylic hydrogen) to still other reactions. Among the chemical reactions of the carbon-carbon double bond that of epoxidation occupies a special niche, because epoxidation is virtually unique to the C=C linkage, because epoxidation proceeds with great specificity, and because the resulting epoxide is a controllably reactive functional group which reacts with a wide range of reagents, schematically represented here as H-Y, to afford an equally wide range of difunctional materials according to the reaction. Although epoxidation may be performed with several different reagents, that variation of greatest interest here is one where the reagent is a hydroperoxide, particularly where epoxidation is catalyzed by a titanium compound. A commercial process uses tertiary butyl or ethylbenzene hydroperoxide in combination with 2% titania supported on silica to epoxidize propylene to propylene oxide with greater than 97% conversion of, for example, ethylbenzene hydroperoxide and selectivities to propylene oxide formation approaching 90%. More recently an Italian group has developed catalysts, referred to as titanium silicalites, where small amounts of framework silicon in silicalite are said to be replaced by titanium and has found such materials conveniently designated as TS-1, to be effective in catalyzing the epoxidation of olefinic compounds by hydrogen peroxide in either the presence or absence of a solvent; see US-A-4410501 and EP-A-0100119 (corresponding to US-A-4833260). Subsequently this has been extended to the epoxidation of olefins with oxygen in air in the presence of a redox system of alkyl anthrahydroquinone and alkyl anthraquinone; EP-A-526945. It has speculated that the observed activity both of titania supported on silica and TS-1 arises from the high dispersion of titanium atoms in a silica lattice, that is, active materials are characterized by Ti(IV) isolated by a long sequence of -0-Si-0-Si-. This conclusion was supported somewhat by the observation that when titania is supported on alumina, magnesia, or zirconia the resulting composite is inactive in epoxidation, and also is supported by the observation that catalyst activity increases as manifested by an increase in epoxide selectivity as the concentration of titania on silica decreases. It has now been found that a catalytic composite of a titanosilicate on titania is demonstrably more active and more selective as a catalyst in the epoxidation of olefinic compounds than are prior art titanium-based catalysts which have been used in epoxidation. This catalytic composite demonstrates greatly increased activity, selectivity, and reusability relative to TS-1. These characteristics make the catalysts obtained by the method of the instant invention uniquely suited for use in the epoxidation of olefins with hydrogen peroxide. WO-A-9412277 is a document falling within the state of the art according to Article 54(3) EPC. It discloses oxidation catalysts consisting of titanium silicalite with MFI structure crystallized in situ and carried on activated charcoal or metal oxide. In one embodiment disclosed in WO-A-8412277, a catalyst is prepared by impregnating a titanium-containing silica sol on metal oxide, precipitation of a TiO 2 -SiO 2 mixture on metal oxide, or precipitation of SiO 2 on metal oxide and impregnation of a titanium compound, and treatment in an autoclave in the presence of a template at autogenous pressure and a temperature from 150 to 200°C over a period of 48 to 240 hours, followed by washing, filtration and tempering in a known manner. The present invention provides a method of producing a catalyst comprising a titanosilicate impregnated on titania by hydrothermal crystallization of the titanosilicate. According to the method of the invention, (a) high purity titania is impregnated with a titanium source and dried, (b) the resulting impregnated titania is mixed with a gel containing both a titanium source and a silicon source (c) the resulting power-in-gel mixture is crystallized under hydrothermal conditions by stirring at a temperature between 150 and 200°C and a pressure of 790 to 1480 kPa (100 to 200 psig), and (d) the crystallized solid is dried and calcined. The catalyst obtained as described above is used in a facile process for the conversion of olefins to their epoxides in high yield and with great selectivity, preferably by the epoxidation of an olefinic compound by hydrogen peroxide in the presence of a titanosilicate deposited on titania. In a more specific embodiment the epoxidation is conducted in purely aqueous media using hydrogen peroxide at a concentration no more than 30 weight percent. In a more specific embodiment the epoxidation is effected with hydrogen peroxide at a concentration not more than 15 weight percent and at a temperature no more than about 100°C. In yet another embodiment the olefinic compound is propylene. Other embodiments are associated with the catalyst system which is produced by hydrothermal crystallization of titanosilicate in the presence of titania particles. A catalyst system comprising titanosilicates supported on titania has now been found to be an extraordinarily effective catalyst in the epoxidation of olefinic compounds using hydroperoxides as the epoxidizing agent. Hydrogen peroxide can be readily utilized, even at concentrations as low as 2 weight percent, and epoxidations often take place at a convenient rate at temperatures in the range of 25-75°C. The feedstock for this reaction contains olefinic compounds generally, with or without a solvent. The olefinic compound can be generally described according to the formula where R 1 , R 2 , R 3 , and R 4 may be hydrogen, alkyl, aryl, cycloalkyl, aralkyl, carboxylic acid, carboalkoxy, a halogen, sulfonic acid, sulfonic acid ester, nitrile, sulfone, or ether group. The alkyl, cycloalkyl, arylalkyl, or aryl groups also may contain, e.g., a carboxylic acid grouping, carboxylic ester grouping, halogen, sulfonic acid or sulfonic ester grouping, nitrile, nitro, hydroxyl, ketone, anhydride, amino, hydroxyl, and ether groupings. As can be appreciated, our invention are useful to an enormous diversity of olefinic compounds. In fact, the major criterion for a suitable feedstock is that it contains non-aromatic carbon-carbon double bond. One large group of olefinic compounds which may be used are the alkenes, especially those containing between 2 and 20 carbon atoms. Such alkenes include ethylene, propylene, butene-1, butene-2, isobutylene, the pentenes, heptenes, hexenes, octenes, nonenes, decenes, undecenes, dodecenes, tridecenes, tetradecenes, pentadecenes, hexadecenes, heptadecenes, octadecenes, nonadecenes, and eicosene. Propylene and the 4-carbon olefins are particularly preferred in the practice of this invention. Dimers and trimers - and low-molecular weight oligomers generally - of the lower alkenes such as ethylene, propylene, and the butenes also are suitable olefinic compounds in the practice of this branch of the invention. The cycloalkenes and the substituted cycloalkenes comprise another class of olefinic compounds which may be used in the practice of our invention. Suitable alkenes include cyclopentene, cyclohexene, cyclooctene, cycloheptene, cyclononene, and cyclodecene. Among other illustrative cyclic olefinic compounds are cyclooctadiene, dicyclopentadiene, methylenecyclopropane, methylenecyclopentane, vinylcyclohexene, methylcyclopentene, ethylcyclopentene, propylcyclopentene, methylcyclohexene, methylcycloheptene, and so forth. Aryl substituted alkenes also may be used generally and include materials such as styrene, 1-phenyl-1-propene, 1-phenyl-2-propene, 2-phenyl-1-propene, the phenyl butenes, phenyl pentenes, phenyl hexenes, phenyl heptenes, divinylbenzene, indene, stilbene, and so forth. The olefinic compounds which may be used may bear other functional groups, either at the olefinic carbons or, more generally, at a position other than the olefinic carbon. For example, alcohols and ethers thereof may be among the functionalized olefinic compounds used as a feedstock in our invention, including such materials as allyl alcohol, allyl methyl ether, allyl ethyl ether, 2-buten-1-ol, 3-buten-2-ol, 3-buten-1-ol, cinnamyl alcohol, alkyl and aryl ethers of the buten-1-ols, 2-methyl-2-propene-1-ol, alkyl ethers of the latter such as the methyl, ethyl, propyl, and butyl ethers, as well as such ethers as the benzyl and phenyl ethers thereof, all of which serve to illustrate the presence of an hydroxyl or ether group in the olefinic compound. Allyl alcohol and their ethers are particularly important inasmuch as the product, glycidol and glycidyl ethers, are important chemical intermediates. Haloalkenes also may be used, particularly where the halogen is not on an olefinic carbon. For example, allyl chloride and allyl bromide afford as the epoxidation product epichlorohydrin and epibromohydrin, resp., both of which are important articles of commerce. Olefinic carboxylic acids and their esters are another class of compounds which may be used in the practice of our invention and may be exemplified by such materials as acrylic acid, alpha-methacrylic acid, 2-butenoic acid, 3-butenoic acid, 2-pentenoic acid, 3-pentenoic acid, 4-pentenoic acid, 2-methyl-2-butenoic acid, 3-methyl-2-butenoic acid, 2-methyl-3-butenoic acid, and so forth. Other unsaturated acids of particular mention as olefinic compounds subject to epoxidation by the process of our invention include cinnamic acid, maleic acid, and fumaric acid, and the large class of unsaturated fatty acids and their esters, especially triglycerides, represented by acids such as linoleic acid, linolenic acid, oleic acid, ricinoleic acid, erucic acid, palmitoleic acid, and the like. Other functional groups may be present in the olefinic compound, especially at the non-olefinic carbons, including such functional groups as the sulfonic acid grouping and their corresponding esters, the nitrile grouping, nitro and ether grouping. Dienes also may be used in epoxidation, especially butadiene. Except in unusual circumstances it must be recognized that dienes can be expected to undergo epoxidation at either C=C bond, hence the selectivity of the epoxidation of dienes can be expected to be low with respect to formation of an epoxide at but one point in the molecule. Consequently dienes, and polyenes more generally, are not favored among the olefinic compounds for this reaction, principally because of the complexity of the resulting reaction mixture. On the other hand, where selectivity of double bond epoxidation is unimportant polyenes may be readily numbered as among the suitable substrates. The epoxidizing agent may be any hydroperoxide, although hydrogen peroxide is preferred by far. Among the organic hydroperoxides may be mentioned the alkyl hydroperoxides, especially tertiary butyl hydroperoxide and, to a lesser extent, the hydroperoxide of ethylbenzene. Peracids form another class of organic compounds furnishing the peroxide linkage and among these peracetic acid, trifluoroperacetic acid, and perbenzoic acid are the most commonly employed peracids. The primary oxidizing agent which is used is hydrogen peroxide, especially as aqueous solutions. Thirty weight percent solutions of hydrogen peroxide in water have been standard in the prior art, but their disadvantage is that of cost. One important advantage of the catalysts obtained according to the present invention is that these catalysts are effective in bringing about epoxidation even with dilute aqueous hydrogen peroxide as the oxidizing agent. Thus, even 2 weight percent aqueous hydrogen peroxide solutions may be employed to convert olefinic compounds to their epoxide in yields in excess of 90% and with virtually 100% efficiency in utilization of hydrogen peroxide. In general, aqueous solutions containing as little as 2% and as much as 70 weight percent hydrogen peroxide may be used, although hydrogen peroxide concentrations of 2-15 weight percent are far more common, and concentrations of 2-10 weight percent are preferred. Where the olefinic compound is epoxidized under heterogeneous conditions, it is preferred to use as concentrated a hydrogen peroxide as is readily available, which generally translates to the use of a 30% hydrogen peroxide solution. The catalyst obtained according to the present invention is a titanosilicate impregnated on titania. More particularly, we believe the catalyst is a composite of small crystallites of a titanosilicate deposited on and affixed to the surface of titania, especially titania of small particle size under 0.5 µm and preferably 0.2 µm or less. The catalysts are made as follows. Small titanium-containing particles are deposited on titania to serve as nucleation points for the subsequent crystallization of a titanosilicate. High purity titania is first impregnated with a titanium source, such as titanocene or a titanium alkoxide, and then dried. The impregnated titania is then mixed with a gel containing both a titanium and a silicon source, such as titanium t-butoxide and tetraethyl silicate, respectively. This powder-in-gel mixture is then crystallized under hydrothermal conditions, which means stirring the powder-in-gel mixture at temperatures of between 150 and 200°C and pressures of 790 to 1480 kPa (100 to 200 psig) for a time usually from 2 to 10 days. Following crystallization the solid is collected, washed well with water, dried, and then calcined. Although we generally use a calcination temperature in the interval of 500 to 550°C, it is not believed that the calcination temperature is a critical variable in the successful preparation of the catalyst and believe temperatures in the range of 400-700°C will suffice. The gel of titanium and silicon sources contains these two elements at a Si:Ti atom ratio of from 5 up to 100, with ratios of 10-40 being the most usual ones. The total amount of titanosilicate crystallized on the titania particles affords a final composite whose composition as titania/silica can be expressed as xTiO 2 (1-x)SiO 2 where x may be as low as 0.1, but usually at least 0.5, and as high as 0.98, with the range between 0.7 and 0.8 favored in the practice of this invention. Catalysts prepared as described above may be used directly or may be ion exchanged with a cation such as an alkali metal or alkaline earth cation. Cation exchange appears to somewhat increase selectivity but this variant is considered optional rather than essential and mandatory. Where cation exchanged material is used exchange with an alkali metal cation, especially that of sodium and potassium, is preferred. Exchange with an alkaline earth metal cation is another variant, one in which the use of magnesium and calcium is preferred. Olefinic compounds are oxidized using principally hydrogen peroxide as the oxidizing agent in the presence of the aforedescribed catalyst under epoxidation reaction conditions. Such reaction conditions include a temperature as low as 0°C up to as high as 100°C. Epoxidation may be conducted at 101.3 kPa (atmospheric pressure) or higher. A major reason to perform the epoxidation at elevated pressure is to increase the solubility of gaseous reactants in the reaction medium. For example, where propylene is epoxidized without the use of a cosolvent increased pressure leads to an increased solubility of the propylene in aqueous solution with an increase in overall rate of propylene epoxide formation. Epoxidation may be performed in either a batch or continuous mode. For example, in a batch mode the olefinic compound, either alone or in an organic solvent, is mixed with an aqueous hydrogen peroxide solution in the presence of an effective amount of a titania supported titanosilicate. The amount of titania supported titanosilicate used per mole of carbon-carbon double bond to be epoxidized may be as low as 3 grams per mole. There is no theoretical limit to the maximum amount of titania-supported titanosilicate to be used, although as a practical matter there is no benefit from using more than about 30 grams per mole of carbon-carbon double bond. The reaction mixture is stirred well at temperatures between 0°C up to as high as 100°C. The hydrogen peroxide may be present at a concentration as low as 2 weight percent and as high as 50 weight percent. Whether the hydrogen peroxide or the olefinic compound is present in excess depends upon the nature of the olefinic compound as well as its cost. For example, where propylene is being epoxidized, unreacted gaseous propylene may be readily recovered and recycled. In such an instance it is advantageous to have the olefinic compound in molar excess, with as much as 2-10 moles per mole of hydrogen peroxide being preferred. However, where a rather expensive, or relatively unavailable olefinic compound is being epoxidized, it may be highly advantageous to use hydrogen peroxide in molar excess, for example in amounts as little as 5-10% molar excess, although molar ratios of up to 10 may be employed. In general, then, the molar ratio of olefinic compound to hydrogen peroxide may range from 1:10 to 10:1. Where the reaction is performed in a continuous mode one may employ any of the conventional process techniques currently known. These include use of a fixed bed process, a continuous stirrer tank reactor process, a radial bed reactor process, and so on. In such cases the catalyst of the invention may be used as pellets, extrudates, spheres, and the like. When the titania supported titanosilicate is used in such forms it is preferable to incorporate a binder for preserving and enhancing catalyst integrity. Conventional binders include silica, alumina, silica-alumina, and various clays, but since such conventional materials are well known to those skilled in the binder art no further detailed discussion will be given. EXAMPLE 1 Preparation of titania-supported titanosilicate catalyst by the method of the invention. High purity titania was first impregnated with a titanium source, such as titanocene or titanium butoxide by mixing 500 g of titania with 2 g of the titanium source in 200 cc of a solvent, such as isopropyl alcohol. Solvent was evaporated and the resulting solid was dried in a vacuum oven overnight at 120°C. A gel from silicon and titanium sources was prepared as follows. Tetraethyl orthosilicate (682.5 g in 300 cc water) and 300 cc isopropyl alcohol was cooled to 10-15°C, and to this was added 150 g of 40 weight percent tetrapropyl ammonium hydroxide and 150 g water to partly hydrolyze the silicon source. To this mixture was added dropwise with vigorous stirring a solution of 33.6 g titanium butoxide in 150 mL isopropyl alcohol. The clear yellow liquid was stirred for about 1 hour at room temperature, after which 450 g of 40 weight percent tetrapropyl ammonium hydroxide and 1650 g distilled water were added to complete the hydrolysis at 80°C for about 6 hours. Approximately 500 g of impregnated titania and 2,000 cc of the gel were added to an autoclave with stirring and crystallization was permitted to proceed under hydrothermal conditions (175°C for 3 days at 1825 - 2170 kPa (250-300 psi) pressure). The crystalline solid obtained was centrifuged, washed with distilled water, dried, and calcined at 550°C in air for 5 hours. Using the foregoing procedure a number of titania-supported titanosilicates were prepared having a range of silicon content representing different values of x in the formula xTiO 2 (1-x)SiO 2 The percentages of titanium, silicon, and the corresponding value of x in the various preparations is summarized in Table 1. Analytical Data for Titania Supported Titanosilicates Sample Si, wt % Ti, wt % x , 1 8.79 49.7 0.77 2 6.73 45.9 0.80 3 1.22 57.4 0.97 4 36.7 9.76 0.13 5 17.6 37.1 0.55 6 9.98 44.9 0.72 EXAMPLE 2 Oxidation of propylene; general procedure. To a Parr reactor was added 40 g of 30 weight percent aqueous hydrogen peroxide, 200 g methanol as a cosolvent, and 1.25-10 g of catalyst. When the desired temperature was reached, liquid propylene was added to the reactor along with nitrogen to a total pressure of 3550 kPa (500 psi). Because the epoxidation is exothermic, the reaction mixture was internally cooled where necessary. Samples were taken periodically and analyzed by gas chromatography. The reaction generally was conducted in the interval of 40-60°C with a molar ratio of propylene:hydrogen peroxide of 5:1. Hydrogen peroxide concentration was measured iodometrically; propylene oxide yield (based on hydrogen peroxide) was determined by gas chromatography. EXAMPLE 3 Comparison of titania supported titanosilicates and TS-1 . In this example there is compared directly TS-1, a 15:85 mixture of TS-1 and titania, and three titanosilicates, Catalysts A, B, and C supported on titania differing in their method of preparation. Catalyst C was prepared as described in Example 1 with titania impregnation by a Ti source prior to deposition of the titanosilicate, and corresponds to sample 2 of Table 1. Catalyst B was prepared without such impregnation and has virtually identical silicon and titanium analysis (x=0.80). Where titania was used a uniform 0.2 micron sized particle was utilized. The results, summarized in Table 2, show quite clearly that not only do the catalysts of the invention show a far greater activity than do the TS-1 catalysts of the prior art, but also are far superior to a physical mixture of TS-1 and titania. It also is interesting to note that the yield with the catalysts of the invention are much greater than afforded by the other materials. Reactions were performed at 40°C using 1.25 g of catalyst, 40 g of 30 weight percent H 2 O 2 , 200 g methanol and 73 g propylene. Comparison of TS-1 with Titania Supported Titanosilicates Catalyst; % Propylene Oxide Formed Time (hrs) TS-1 A B C 0 0 0 0 0 0.25 5.9 9.2 38.6 40.9 0.5 16.1 18.9 51.4 66.2 1 21.1 23.9 67.1 71.7 3 28.5 33.1 70.8 80.9 0 34.9 38.6 82.9 90.1 EXAMPLE 4 Effect of reaction temperature, contact time, and catalyst amount on propylene oxide yield. In this example contact time, reaction temperature, and the amount of catalyst used was varied in order to study their effects on propylene oxide yield. Tables 3 and 4 summarize these results. The catalyst used was sample 6 of Table 1 and had a surface area of 91 m 2 /g. Effect of Temperature on Propylene Oxide Formation (10 g. catalyst) Time (hours) % Propylene Oxide Formed 30°C 40°C 50°C 1 46 62 79 3 62 74 81 4 73 79 85 5 80 85 92 6 93 93 95 H 2 O 2 Conversion after 6 hours 100 100 100 Effect of Catalyst Amount on Propylene Oxide Formation at 40°C Time (hours) Catalyst Amount C 2.5 g 5 g 10 g 1 35 42 61 3 41.3 58.5 74 4 45.7 60 79 5 50.8 67.5 81 6 60.9 87 93 H 2 O 2 Conversion after 6 hours 63 90 100 EXAMPLE 5 Catalyst reusability. The general conditions for epoxidation were those described in Example 2. After each epoxidation reaction, the catalyst (sample 2 of Table 1) was recovered by centrifugation and reused, without any additional treatment, in a subsequent epoxidation. Table 5 shows the yield of propylene oxide after 6 hours reaction attained after 1, 2, 3 and 4 reuses. The data show quite clearly that the catalyst manifests virtually no decrease in activity. Catalyst Reusability Cycle T, °C Propylene Oxide % H 2 O 2 Conversion % Yield % Selectivity 1 60 90 91 100 2 40-60 93 93 100 3 40-60 98 94 100 4 40 94 94 97

Claims: A method of producing a catalyst comprising a titanosilicate impregnated on titania by hydrothermal crystallization of the titanosilicate, wherein (a) high purity titania is impregnated with a titanium source and dried, (b) the resulting impregnated titania is mixed with a gel containing both a titanium source and a silicon source (c) the resulting powder-in-gel mixture is crystallized under hydrothermal conditions by stirring at a temperature between 150 and 200°C and a pressure of 790 to 1480 kPa (100 to 200 psig), and (d) the crystallized solid is dried and calcined. A method according to Claim 1 characterized in that the titanium source in step (a) is titanocene or a titanium alkoxide. A method according to Claim 1 or 2 characterized in that the titanium source in step (b) is titanium t-butoxide. A method according to any one of Claims 1 to 3 characterized in that the silicon source in step (b) is tetraethyl silicate. A method according to any one of Claims 1 to 4 characterized in that the calcining in step (d) is carried out at a temperature of 400 to 700°C. A method according to any one of Claims 1 to 5 characterized in that the atom ratio of silicon to titanium in the titanium and silicon sources of step (b) is from 5 to 100.

Inventors: JONES RICHARD RILEY, MALLOY THOMAS P, NEMETH LASZLO T, JONES, RICHARD RILEY, MALLOY, THOMAS P., NEMETH, LASZLO T.
Applicants: UOP INC, UOP
Application year: 1994
Main classification: B01J29
IPC codes: C07D301, B01J29